1999 BMW 525i Workshop Manual

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7 Maintenance
< Unbolt caliper from steering arm to properly inspect:
Brake pad thickness
(A)
Brake rotor
Condition of caliper seal
(B)
Condition of caliper slider bolts (C)
NOTE-
Brake caliper removal and installation procedures are given
in
340 Brakes.
Brake pad lining minimum thickness
Dimension
A 3.0 mm (0.12 in)
Brake system, inspecting
Routine maintenance of the brake system includes maintain-
ing the brake fluid in the reservoir,
checking bralte pads for
wear, checking parking brake function, and inspecting the
system for fluid lealts or other damage:
- Check that bralte hoses are correctly routed to avoid chafing
or
Itinking.
- lnspect unions and brake calipers for signs of fluid leaks.
- lnspect rigid lines for corrosion, dents, or other damage.
- Inspect flexible hoses for cracking
- Replace faulty hoses or lines as described in 340 Brakes.
WARNING-
Incorrect installation or overtightening hoses, lines, and
unions may cause chafing
orlealage. This can lead to partial
Parking brake, checking
The parking brake system is independent of the main braking
system and may require periodic adjustment depending on
use. Adjust the parking brake if the brake lever can be pulled
up more than
8 clicks. Check that the cable moves freely. A
description of the parking brake and
parlting bralte adjust-
ment can be found in
340 Brakes.

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020-26
Maintenance
NOTE-
The parking brake may lose some of its effectiveness if it is
not used frequently This is due to corrosion build-up on the
parking brake drum. To remove corrosion, apply the parking
brake just until it begins to grip, then pull the lever up one
more stop (click). Drive the car approximately 400 meters
(1,300
ft.) and release the brake. To recheck the adjustment
of the parking brake see
340 Brakes.
Clutch fluid, checking
In cars equipped with manual transmission and clutch, the hy-
draulic clutch and the brake system share the same reservoir
and the same bralte fluid. Clutch fluid level and brake fluid lev-
el are checked at the same time.
NOTE-
* See 340 Brakes for more information.
See
210 Clutch for information on the clutch and the
hydraulic clutch operating system.
Differential oil level, checking
The E39 differential is filled with lifetime oil that ordinarily
does not need to be changed.
BMW recommends using only
a specially formulated synthetic gear oil
(SAF-XO) that is
available through an authorized
BM\N dealer parts depart-
ment. For additional information on this lubricant and any
other lubricants that may be compatible, contact an
authorized
BMW dealer service department.
< Check rear differential oil level at filler plug (arrow).
- Check lubricant level with car on a level surface:
Level is correct when fluid just reaches edge of filler hole.
If necessary, top up fluid.
Replace filler plug sealing ring.
Install and tighten oil filler plug when oil level is correct.
NOTE-
Use either a 14 mm or 17 mm Allen socket to remove the
drain plug.
If the car is raised in the air, it should be level when
checking or filling final drive fluid level.
Tightening torque
Filler plug to final drive housing 70 Nrn (52 it-lb)

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.-. -
Maintenance
Drive axle joint
(CV joint) boots, inspecting
CVjoint protective boots must be closely inspected forcracks
and any other damage that will allow contaminants to get into
the joint.
If the rubber boots fail, the water and dirt that enter
the joint will quickly damage it.
NOTE-
Replacement of the CVjoint boots and inspection of the
joints are described
in 331 Final Drive.
Exhaust system, inspecting
Exhaust system life varies widely according to driving habits
and environmental conditions. If short-distance driving pre-
dominates, the moisture and condensation in the system will
not fully dry out. This will lead to early corrosion damage and
more frequent replacement.
Scheduled maintenance of the exhaust system is limited to
inspection:
* Check to see that all the hangers (arrow) are in place and
properly supporting the system and that the system does
not strike the body.
Check for restrictions due to dents or
kinlts,
Check for weakness or perforation due to rust.
NOTE-
Alignment of the system and the location of the hangers are
described in
180 Exhaust System.
Fuel filter, replacing
The fuel filter is located beneath the center of the car, approx-
imately under the driver's seat.
A protective cover must be
removed to access the filter.
4 Fuel filter for M62 engine (arrow)
- Disconnect battery negative (-) cable
CAUTIOI\C
Disconnecting the battery cables may erase fault codes
stored
in engine control module memory.
WARNING -
Fuel will be expelled forcibly when the filter is removed. Do
notsmoke or work near heaters orother fire hazards. Keep a
fire extinguisher handy

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020-28
1 Maintenance
- When replacing fuel filter:
Use appropriate hose clamping device to clamp off filter
inlet and outlet hoses to lessen fuel spillage.
Loosen center clamping bracket and hose clamps on
either end of filter.
Note arrow or markings indicating direction of flow on
new filter.
Install new filter using new hose clamps
- Drain fuel filter from inlet side into a container and inspect
drained fuel.
Checlc for rust, moisture and contamination.
I - I < If fuel filter is equipped with fuel pressure regulator:
I 2 / Remove vacuum hose (1)
Pull out locking clip (2).
- Remove fuel pressure regulator (3).
Install pressure regulator in new filter.
Clean thoroughly around the filler connections before
removing them.
After assembly, check filter connections carefully for
I
I lealcs before installing cover.
NOTE- ~-
Additional informarion about the fuel filler assembly is in 160
Fuel Tank and Fuel Pump.
Fuel tank and fuel lines, inspecting
lnspectthe fuel tank, fuel lines, and fuel system fordamage or
lealts. Checlc for fuel lealts in the engine compartment or fuel
odors in the passenger compartment. Check for any evapora-
tive emissions hoses that may have become disconnected,
checking carefully at charcoal canister and evaporative emis-
sions purge system. See
130 Fuel Injection and 160 Fuel
Tankand Fuel Pump for component locations and additional
information.
WARNING-
When checlcing for fuel leal(s, the engine must be cold. A hot
exhaust manifold or exhaust system could cause the fuel to
ignite or explode causing serious personal injury Ventilate
the work area and clean up spilled fuel immediately.

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Maintenance
Suspension, front, inspecting
Inspection of the front suspension and steering includes a
check of all moving parts
forwear and excessive play. Inspect
ball joint and tie-rod rubber seals and boots for cracks
ortears
that could allow the entry of dirt, water, and other
contaminants. See
310 Front Suspension.
Suspension, rear, inspecting
Differential and rear drive axle service consists of checking
and changing the gear oil, inspecting for leaks, and checking
the drive axle
CV joint boots for damage.
The areas where
lealts are most likely to occurare around the
drive shaft and drive axle mounting flanges. For more infor-
mation on identifying oil leaks and theircauses, see
330 Rear
Suspension and
331 Final Drive.
Tires, checking inflation pressure
Correct tire pressures are important to handling and stability,
fuel economy, and tire wear. Tire pressures change with tem-
perature. Pressures should be
checked oRen during season-
al temperature changes. Correct inflation pressures can be
found on the driver's door pillar and in the owner's manual.
Note that tire pressures should be higher when the car is
more heavily loaded.
WARNING-
Do not inflate any tire to a pressure higher than the tire's max-
imum inflation pressure listedon the sidewall. Use care when
adding air to warm tires. Warm tire pressures can increase as
much as
4 psi (0.3 bar) over their coldpressures.
Tires, rotating
BMW does not recommend tire rotation. Due to the car's sus-
pension design, the front tires begin to wear first at the outer
shoulder and the reartires begin to wearfirst at the middle of
the tread or inner shoulder. Rotating the tires may adversely
affect road handling and tire grip.
Transmission service, automatic
The automatic transmissions installed in E39 models are
filled with special automatic transmission fluid. The transmis-
sion lubricant type can be found on the "type-plate" on the
side of the transmission. The recommended lubricants are
listed earlier in this repair group. See Fluids and lubricants.
If in doubt, consult an authorized BMW dealer for alternate

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020-30
Maintenance
fluid use and the most-up-to-date information regarding
transmission operating fluids.
The automatic transmission is not equipped with a dipstick.
Therefore, checking the ATF level is an involved procedure
which includes measuring and maintaining a specified ATF
temperature during the checking procedure.
For more complete
ATF service information, including
checking
ATF level and ATF filter replacement procedures,
see
240 Automatic Transmission.
Transmission service, manual
Manual transmission service consists of inspecting for leaks
and checking the fluid. Evidence of transmission leaks is
like-
ly to be seen around the driveshaft mounting flange and at the
bottom of the bellhousing.
NOTE-
For more information on identifying oil
leaks and their
causes, see 230 Manual Transmission and210 Clutch.
Transmission fluid, checking and filling
(manual transmission)
Tne manual transmss'on inslalleo 'n rne E39 models s f;lled
with a special liierime iluid (ivlTF-LT-I). oi. ordinarily
does
not need to be changed.
< Check manual transmission oil level at transmission filler plug
(A). Make sure car is on level surface.
NOTE- Transmission fluid level
checking and replacement
procedures are covered in 230 Manual Transmission.
Wheels, aligning
BMW recommends checking the front and rear alignment
once a year and whenever new tires are installed.
NOTE-
See 320 Steering and Wheel Alignment for a more detailed
discussion of alignment requirements and specifications.

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Maintenance
BODY AND INTERIOR MAINTENANCE
Body and hinges, lubricating
Door locksand loclccylinderscan be lubricated with an oil that
contains graphite.
Body and doorhinges, hood latch and doorcheclc rods should
be lubricated with
SAE 30 or SAE 40 engine oil. Lubricate
seat runners with multipurposegrease. Do not apply any oil to
rubber parts.
If door weather-strips are sticking, lubricate
them with silicone spray or talcum powder. The hood release
cable should be lubricated as well.
The use of winter
lock deicer sprays should be lkept to an
absolute minimum, as the alcohol in the deicer will wash the
grease out of the lock assemblies and may cause locks to
corrode internally or to become difficult to operate.
Exterior washing
The longer dirt is left on the paint, the greater the risk of dam-
aging theglossy finish,
eitherby scratching or by thechemical
effect dirt particles may have on the painted surface.
Do not wash the car in direct sunlight. If the engine hood is
warm, allow it to cool. Beads of water not only leave spots
when dried rapidly by the sun or heat from theengine, but also
can act as small magnifying glasses and burn spots into the
finish. Wash the car with a mixture of lukewarm water and a
car wash product. Rinse using plenty of clear water. Wipe the
body dry with a sofl cloth towel or chamois to prevent
water-spotting.
Interior care
Dirt spots can usually be removed with lultewarm soapy water
or a dry foam cleaner. Use spot remover for grease and oil
spots. Do not pour the liquid directly on the carpet or fabric,
but dampen a clean cloth and rub carefully, starting at the
edge of the spot and working inward. Do not use gasoline,
naphtha, or other flammable substances.
Leather upholstery and trim
Leather upholstery and trim should be periodically cleaned
using a slightly damp cotton or wool cloth. The idea is to get
rid of the dirt in the creases and pores that can cause brittle-
ness and premature aging. On heavily soiled areas, use a
mild detergent (such as
wooliteQ) or other specially formulat-
ed leather cleaners. Dry the trim and upholstery completely

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020-32
Maintenance
using a soft cloth. Regular use of a good quality leather condi-
tioner will reduce drying and cracking of the leather.
Polishing
Use paint polish only if the finish assumes a dull loolc afler
long service. Polish can be used to remove tar spots and tar-
nish, but
afleiwards a coat of waxshould be applied to protect
the clean finish. Do not use abrasive polish or cleaners on
aluminum trim or accessories.
Seat belts
Dirt and other abrasive particles will damage seat belt web-
bing. If it is necessary to clean seat belts, use a mild soap so-
lution. Bleach and other strong cleaning agents may weaken
the belt webbing and should be avoided.
WARNING-
Do not clean the seat belt webbing using dry cleaning or oth-
er chemicals. Allow wet belts to
dry before allowing them to
retract.
-
The condition of the belt webbing and the function of the re-
tractor mechanisms should be inspected. See
720 Seat Belts
for seat belt inspection information.
Speciai cieaning
Tarspots can be removed with a bug and tar remover. Never
use gasoline,
lterosene, nail polish remover, or other unsuit-
able solvents. Insect spots also respond to tar remover.
A bit
of baking soda dissolved in the wash water will facilitate their
removal. This method can also be used to remove tree sap
spots.
Washing chassis
Periodic washing of the underside of the car, especially in
winter, will help prevent accumulation of road salt and rust.
The best time to wash the underside is just afler the car has
been driven in wet conditions. Spray the chassis with a pow-
erful jet of water. Commercial or self-service carwashes may
not be bestforthis, as they may recycle the salt-contaminated
water.
Waxing
For a long-lasting, protective, and glossy finish, apply a hard
wax after the car has been washed and dried. Use carnauba
or synthetic based products. Waxing is not needed after
every washing. You can tell when waxing is required by
look-